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TRANSCRIPT
INTRODUCTION
CHAPTER-1
INTRODUCTION
1.0 General
Currently India has taken a major initiative in developing the infrastructures such as express
highways, Power projects, Industrial structures, Bridges and Tunnels etc., to meet the
requirements of globalization, in the construction of buildings and other structures Concrete
plays a rightful role and a large quantum of concrete is being utilized. River sand, which is one
of the constituents used in the production of conventional concrete, has become highly expensive
and also scarce. In the backdrop of such a bleak atmosphere, there is large demand for alter
native materials from industrial waste.
The consumption of cement content, workability, Compressive strength and cost of
concrete made with quarry dust were studied by researchers Babu K.K, Nagraj T.S,
Narasimahan. The Mix design proposed by Nagaraj shows the possibilities of ensuring the
workability by wise combination of rock dust and Sand, use of super plasticizer and optimum
water content using generalized lyse rule. Sahu A.K reported significant increase in compressive
strength, modulus of rupture and split tensile strength when 40 percent of sand is replaced by
quarry rock dust in concrete. Ilangovan and Nagamani reported that Natural sand with quarry
dust as full replacement in concrete as possible with proper treatment of Quarry dust before
utilization.
The utilization of quarry rock dust which can be called as manufactured sand has been
accepted as building material in the industrially advanced countries of which West for the past
there decades. As a result of sustained research and development works under-taken with respect
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to increasing application of this industrial waste. The level of utilization of Quarry rock dust in
the industrialized nations like Australia, France, Germany and UK has been reached more than
60% of its total production. The use of manufactured sand in India has not been much, when
compared to some advanced Countries.
1.1 Introduction to Ordinary Portland Cement (OPC)
Ordinary Portland cement (OPC) is the most important type of cement. Prior to 1987,
there was only one grade of OPC governed by IS269-1976. After 1987, higher grade cements
were introduced in India and OPC was classified into three grades, namely 33 grade, 43 grade
and 53 grade depending upon its strength at 28 days when tested as per IS 4031-1988. The 28
days strength shall be not less than 33 N/mm2, 43 N/mm2, 53 N/mm2 respectively for 33, 43 and
53 grades of cements. But the actual strength obtained by these cements at the factory are much
higher than the BIS specifications.
It has been possible to upgrade the qualities of cement by using high quality limestone,
modern equipments, and closer on line control of constituents, maintaining better particle size
distribution, finer grinding and better packing. Generally use of high grade cement offers many
advantages for making stronger concrete. Although they are little costlier than low grade cement,
they offer 10-20% saving in cement consumption directly besides several other hidden benefits.
One of the most important benefits is the faster rate of development of strength. In the modern
construction activities, higher grade cements have become so popular that 33 grade cement is
almost out of the market.
The manufacture of OPC is decreasing all over the world in view of the popularity of
blended cement on account of lower energy consumption, environmental population, economic
and other technical reasons. In advanced western countries, the use of OPC is as low as 40% of
the total cement production. In India for the year 1998-99 out of the total cement production i.e.,
79 million tons, the production of OPC in 57.00 million tons i.e., 70 %. The production of PPC is
16 million tons i.e., 19% and slag cement is 8 million tons i.e., 10%. In the years to come the use
of OPC still come down, but it will remain as an important type of cement for construction
purposes.3
1.2 Introduction to Quarry Stone Dust
Quarry Stone dust aggregates are a byproduct of the Coarse aggregates like 40mm, 20mm
etc. It is in the form of a poorly graded aggregate with the mixture of Stone powder and small
particles of Stones. It is considered as waste materials of the quarries and are left and dumped as
waste. The Quarry stone dust is collected from a locally available quarry near Himayath sagar
dam.
1.3 Introduction to Fly Ash
Fly ash is one of the numerous substances that cause air, water and soil pollution, disrupt
ecological cycles and set off environmental hazards. The combustion of powdered coal in
thermal power plants produces fly ash. The high temperature of burning coal turns the clay
minerals present in the coal powder into fused fine particles mainly comprising aluminium
silicate. Fly ash produced thus possesses both ceramic and pozzolanic properties. When
pulverised coal is burnt to generate heat, the residue contains 80 per cent fly ash and 20 per cent
bottom ash. The ash is carried away by flue gas collected at economiser, air pre-heater and ESP
hoppers. Clinker type ash collected in the water-impounded hopper below the boilers is called
bottom ash. The process of coal combustion results in fly ash. The problem with fly ash lies in
the fact that not only does its disposal require large quantities of land, water, and energy, its fine
particles, if not managed well, by virtue of their weightlessness, can become airborne. Currently,
90 million tonnes of fly ash is being generated annually in India, with 65 000 acres of land being
occupied by ash ponds. Such a huge quantity does pose challenging problems, in the form of
land usage, health hazards, and environmental dangers. Both in disposal, as well as in utilization,
utmost care has to be taken, to safeguard the interest of human life, wild life, and environment.
1.3.1 Fly ash use in Concrete:
Past research proved better performance characteristics, in response of fly ash concrete,
in terms of durability of concrete almost unanimously across the globe. The improvement in the
gel structure caused by pozzalanic action of fly ash leads to a very impervious concrete. This
factor improves the resistance of concrete against external aggression. Fly ash, an environmental
hazard, can be consumed constructively and thus contribute to the ecological balance by
effectively using it in concrete. As a partial replacement to cement, fly ash is very energy
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efficient and also contributes to economy resulting in large financial savings. Typically, concrete
made with fly ash will be slightly lower in strength than straight cement concrete up to 28 days,
equal strength at 28 days, and substantially higher strength within a year’s time. Thus, fly ash
concrete achieves significantly higher ultimate strength than can be achieved with conventional
concrete.
1.3.2 Physical requirements for Fly ash:
a) Fineness - Specific surface in m2/kg by Blaine’s permeability method, min 320
b) Particles retained on 45 micron IS sieve (wet sieving) in percent, Max 34
c) Lime reactivity - Average compressive in N/mm2, Min 4.5
d) Compressive strength at 28 days in N/mm2, Min Not less than 80 percent of the strength
of corresponding Plain cement mortar cubes
e) Soundness by autoclave test expansion of specimens, percent, Max 0.8
f) Specific gravity - 1.90-2.55
1.3.3 Benefits/Advantages of use of Fly ash in Concrete:
1. Enhances Concrete Workability: The “ball-bearing” effect of fly ash particles creates a
lubricating action when concrete is in its plastic state. This creates benefits in:
a) Ease of Pumping: Pumping requires less energy and longer pumping distances are
possible.
b) Improved Finishing: Sharp, clear architectural definition is easier to achieve, with less
worry about in-place integrity.
c) Reduced Bleeding: Fewer bleed channels decrease permeability and chemical attack.
Bleed streaking is reduced for architectural finishes.
d) Reduced Segregation
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2. Increasing Concrete Performance: In its hardened state, fly ash creates additional benefits for
concrete, including:
a) Higher Strength: Fly ash continues to combine with free lime, increasing
compressive strength over time.
b) Decreased Permeability: Increased density and long term pozzolanic action of fly ash,
which ties up free lime, results in fewer bleed channels and decreases permeability
c) Increased Durability: Dense fly ash concrete helps keep aggressive compounds on the
surface, where destructive action is lessened. Fly ash concrete is also more resistant to
attack by sulfate, mild acid, soft (lime hungry) water, and seawater.
d) Reduced Sulfate Attack: Fly ash ties up free lime that can combine with sulfates to
create destructive expansion.
e) Reduced Corrosion: By decreasing concrete permeability, fly ash can reduce the rate
of ingress of water, corrosive chemicals and oxygen — thus protecting steel
reinforcement from corrosion and its subsequent expansive result. .
f) Reduced Efflorescence: Fly ash chemically binds free lime and salts that can create
efflorescence, and dense concrete holds efflorescence producing compounds on the
inside.
g) Reduced Shrinkage: The largest contributor to drying shrinkage is water content. The
lubricating action of fly ash reduces water content and drying shrinkage. .
h) Reduced Heat of Hydration: The pozzolanic reaction between fly ash and lime
generates less heat, resulting in reduced thermal cracking when fly ash is used to
reduce Portland cement.
i) Reduced Alkali Silica Reactivity: Fly ash combines with alkalis from cement that
might otherwise combine with silica from aggregates, causing destructive expansion.
j) Increased Resistance to Freezing and Thawing
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3. Environmental Benefits:
a) Conserves natural resources: Using recovered fly ash conserves natural resources by
eliminating the need to produce new raw materials. .
b) Conserved Landfill Space: Conserving landfill space by utilizing fly ash is an obvious
environmental benefit. Just 1 ton of fly ash use avoids landfill requirement corresponding
to 455 days of solid waste produced by an average American.
c) Reduces greenhouse gas emission: Fly ash use can also significantly decrease greenhouse
gas emissions. When fly ash is used to replace cement, it reduces the need for cement
production - a highly energy-intensive process that also creates significant amounts of
greenhouse gases.
1.4 Scope for the Present Study
The present work is intended to study and compare the properties of the concrete for two
different mixes of Conventional concrete of M-20 Grade and High strength concrete of M-40
Grade with the percentage replacement of Sand with Quarry stone dust. To achieve this
objective, two concretes of M-20 Grade and M-40 Grade strengths, designed as per Indian code
(IS: 10262-1982), are considered. In the first phase of the test programme, the Compressive
strength of cubes and Split Tensile strength of cylinders are studied by varying the percentage of
Quarry Stone Dust by 0%, 25%, 50%, 100% . The strengths are obtained for different curing
periods (7, 14 & 28 days) is studied. In the second phase of the test programme, the concrete of
M-20 Grade the percentage of Quarry Stone dust is fixed at 50% and to that proportion
replacement of Cement is done in the proportion of 10%, 20%, 30%, and 40%. The compressive
and /split tensile strengths for the specimens are obtained for different curing periods (7, 14 &
28 days) is studied. Likewise the concrete of M-40 Grade the percentage of Quarry Stone dust is
fixed at 25% and to that proportion replacement of Cement is done in the proportion of 10%,
20%, 30%, 40%. The compressive and split tensile strengths for the specimens are obtained for
different curing periods (7, 14 & 28 days) are studied.
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1.7 Objective of the Present Work
The main objective of the study is
• To compare the effect of the percentage replacements of Sand with Quarry Stone Dust in
concrete of M-20 Grade strengths.
• To compare the effect of the percentage replacements of Sand with Quarry Stone Dust in
concrete of M-40 Grade strengths
• To obtain Optimized percentage of replaced materials.
1.8 SUMMARY
In this chapter, theoretical study on different concretes mix, fine aggregate, Quarry
sand and its advantages, application of stone dust, fly ash uses in concrete and its benefits has
been discussed. Also the need for present work, the scope and objective of the present study are
discussed. Based on the objective of the present study, research papers were collected and
studied. The review of research papers is discussed in the next chapter.
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LITERATURE REVIEW
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CHAPTER-II
LITERATURE REVIEW
2.1 General
A Comprehensive literature survey was carried out to review the past work in the area
of influence of replacement of Fine aggregates by Quarry dust on the mechanical properties
of concrete.
2.2 Literature review
M. Shahul Hameed and A.S.S.Sekar (2009) studied the addition of industrial waste improves
the physical and mechanical properties. The kind of innovative concrete requires large amount of
fine particles. Due to its high fineness of the marble sludge powder it provided to be very
effective in assuring very good cohesiveness of the concrete. They have concluded that the
quarry dust and the marble sludge powder may be used as a replacement material for fine
aggregate. The chemical composition of quarry rock dust and marble sludge powder such as
Fe2O3, MnO, Na2O, MgO, K2O, Al2O3, CaO and SiO2 are comparable with that of cement. The
replacement of fine aggregates with 50% marble sludge powder and 50% Quarry rock dust gives
an excellent result in strength and quality aspect. The results showed that the M40 mix induced
higher higher compressive strength, Splitting tensile strength. Increase the marble sludge powder
content by more than 50% improves the workability but effects the compressive strength and
split tensile strength of concrete. The combined effect of quarry rock dust and marble sludge
powder exhibit excellent performance due to efficient micro filling and pozzolanic activity.
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Anupama P.S, Nazeer M, Nizad A, Suresh S (2010) carried out experimental Studies to find
out the feasibility of using quarry dust to partially replace sand in Concrete. These studies
revealed that, due to increased fineness, the combination require an increased water cement ratio
which results in strength reduction or the use of water reducing admixtures. Use of Super
pozzolanic supplementary material such as Silica fume, rice husk ash, metakaolin etc in concrete
and mortar improves strength even at higher water binder ratio. The effect of water binder ratio
and the metakaolin replacement level on the compressive strength of cement quarry dust mortar
was investigated. The inclusion of metakaolin results in faster early age strength development of
mortar. Mix with 15% metakaolin is superior in all water/binder ratios investigated. The drop in
compressive strength due to conversion reaction, decrease with increase in meatkaolin content
for a given water/binder ratio. Also this drop in compressive strength is almost disappeared in
mixes made of higher water binder ratios. Metakaolin admixed mortar reaches their maximum
density at 0.45 w/b ratio for a mix containing 10% matakaolin.
R. Ilangovan, Dr. K Nagamani. (2007) studied the effect of replacement of Fine aggregate by
Quarry stone dust. The experimental investigations were carried and Compressive strength, Split
tensile strength values were taken up. The workability tests were also carried out for different
mixes. A mix design is also suggested on the basis of the investigation. The experiment suggests
the full replacement of Natural Sand by Quarry stone dust.
Monasseh Joel (2010), had done an experimental investigation on the influence of replacement
of Makurdi river Natural sand by Crushed Granite Fine. Shows that replacement will require a
higher water cement ratio, when compared with the values obtained with the use of only Makurdi
river sand. Peak compressive strength and indirect tensile strength values 40.70N/mm2 and
2.30N/mm2 respectively were obtained when Mukurdi river sand was replaced with 20% CGF in
concrete production. Peak compressive strength and indirect tensile strength values 33.07N/mm2
and 2.04N/mm2 respectively were obtained when Mukurdi river sand was replaced with 20%
CGF in concrete production. Based on the findings from the study the partial replacement of
Mukurdi river sand with 20% CGF is recommended for use in concrete production for use in
rigid pavement. Where crushed granite is in abundance and river sand is scare, the complete
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replacement of river sand with CGF is recommended for use in low to moderately trafficked
roads.
R.Ilangovana, N. Mahendrana and K Nagamanib (2008) states that the physical and chemical
properties of quarry rock dust is satisfied the requirement of code provision in properties studies
(Table 1 and 2). Natural river sand, if replaced with hundred percent Quarry Rock Dust form
quarries, may sometime give equal or better than the reference concrete made with natural sand,
in terms of Compressive and Flexural Strength studies. Studies reported shows that the strength
of Quarry Rock Dust concrete is comparatively 10-12 percent more than that of similar mix of
conventional concrete. Also the result of this investigation shows that drying shrinkage strains of
quarry dust concrete are quite large to the shrinkage strain of conventional concrete. The
durability of quarry rock dust concrete under sulphate and acid action is higher inferior to the
conventional concrete. Permeability test results clearly demonstrates that the permeability of
quarry rock dust concrete is less compared to that of conventional concrete. The water absorbtion
of the quarry rock dust concrete is slightly higher than that of conventional concrete.
Norazila Binti Kamarulzaman (2010) have investigated a Study on the effect of quarry dust
as sand replacement material on compressive and flexural strength of foam concrete was
conducted. This study was conducted to determine the compressive strength and flexural strength
of foam concrete by using quarry dust as partial sand replacement material. This presents the
feasibility of the usage of quarry dust as 10%, 20% and 30% substitutes for sand in foam
concrete. Mix design was developed for four different proportion of quarry dust in foam
concrete. Tests were conducted on cubes and beams to study the strength of concrete made of
quarry dust and results were compared with the control foam concrete. It is found that
compressive and flexural strength of foam concrete made of quarry dust are nearly 40% more
than the control foam concrete.
M R Chitlange (2010) studied the properties of concrete by replacing the Natural sand with
artificial sand. It is observed that artificial sand as fine aggregates gives consistently higher
strength than the mixes with natural sand. The sharp edges of the particles in artificial
sand provide better bond with cement than the rounded particles of natural sand resulting
in high strength. There is a marginal increase in compressive strength up to 7% and a
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noticeable increase in flexural and split tensile strength ie about 17%. It is observed that
use of admixture is necessary in all grades of concrete to restrict water cement ratio to 0.5
and below from the desired workability, specifically in artificial sand concrete. The
excessive bleeding of concrete of concrete is reduced by using artificial sand.
S N Raman, M F M Zain, H B Mahmud and K S Tan (2010) studied the stability of Quarry
dust as partial replacement material for sand in concrete. The properties of quarry dust that were
determined were aggregate crushing value, flakiness index, pH value, Soundness, specific
gravity, absorption and fineness module beside the 28 day compressive strength of concrete
specimens in which partial replacement of river sand with quarry dust were practiced, is also
reported for comparison purposes. Results obtained indicate that the incorporation of the quarry
dust in concrete mix as partial replacement material to river sand resulted in lower 28 day
compressive strength. This can partly be attributed to the properties of the quarry dust which
might contribute to the negative effects in the strength of the concrete. This also indicates that
quarry dust can be utilized as partial replacement material to sand, in the presence of silica fume
or fly ash, to produce concrete with fair range of compressive strength.
A K Sahu, Sunil Kumar and A K Sachan (2010) investigated effects of the replacement of
Sand with Crushed stone in concrete. There is a significant increase in compressive strength,
modulus of rupture and split tensile strength for both the concrete mixes when sand is partially
replaced by stone dust. The workability of the concrete mixes decrease with the increase in the
percent of stone dust as partial replacement of sand. The workability of the concrete mixes
increase with the increase in percentage of super plasticizer. If 40% sand is replaced with stone
dust in concrete, it will not only reduce the cost of concrete but also will save large quantity of
natural sand.
Chaturanga Lakshani Kapugamage (2010) studied the effect of Optimizing concrete mixes by
concurrent use of fly ash and quarry dust. The decrease in early strength by addition of fly ash is
ameliorated by addition of quarry dust. The decrease in workability by the addition of quarry
dust is reduced by the addition of fly ash. The loss in early strength due to addition of 15% fly
ash can be completely negated by the addition of 30% quarry dust. The strength at 28 day has
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not been adversely at all by the addition of up to 30% of fly ash. The addition of quarry dust
causes a loss in slump, though such loss in slump can be significantly reduced by the addition of
fly ash.
Radhikesh P Nanda, Amiya K Das, Moharana N C (2010) carried out an experimental
investigation to study Stone crusher dust as a fine aggregate in concrete for paving blocks.
Replacement of fine aggregate crusher dust up to 50% by weight has a negligible effect on the
reduction of any physical and mechanical properties like compressive strength, flexural strength,
split tensile strength etc. Water absorption is well below the limit as per Indian codes. Durability
shows no variation for different replacements of crusher dust.
2.3 APPRAISAL FOR LITERATURE REVIEW
Research on the above Literature reviews shows that Quarry dust was replaced with
Natural Sand with the clear intension of cost saving. An economy criterion is the governing
factor in choosing the replacement material for Natural sand to Quarry Stone dust. The Literature
shows that replacing Natural Sand with Quarry dust at different percentages were showing good
results or at least equal results with that of only Natural sand. So the replacement of Natural Sand
with Quarry Stone dust seems Feasible.
2.4 SUMMARY
In this chapter, the available papers on replacement of natural sand with Quarry stone
dust are discussed. The reviews of the above papers suggest that quarry sand can be used. The
experimental programme of the present study is discussed in the next chapter.
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EXPERIMENTAL PROGRAMME
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CHAPTER-III
EXPERIMENTAL PROGRAMME
3.0 GENERAL
The present investigations are aimed at studying the effect of replacement of Sand with Quarry
Stone Dust on the compressive strength and Split Tensile strength of Conventional Concretes
and High Strength Concrete. The experimental program has two phases. In the first phase, a total
of 72 cubes were cast and tested. The specimens were cast with M-20 Grade and M-40 Grade
strengths by using ordinary Portland cement (OPC-53) with varying the percentages of Sand
with Quarry Stone dust (0%, 25%, 50%, and 100%). The specimens were cast using standard
cubes (150mm X 150mm X 150mm) and cured by conventional curing. Likewise, a total of 72
cylinders were also cast and tested. The specimens were cast with M-20 Grade and M-40 Grade
strengths by using ordinary Portland cement (OPC-53) with varying the percentages of Sand
with Quarry Stone dust (0%, 25%, 50%, and 100%). In the second phase, a total of 72 cubes
were cast and tested. The specimens were cast with M-20 Grade and M-40 Grade concrete. This
time 36 cubes were cast of M-20 Grade Concrete by fixing the percentage replacement of Sand
with Quarry Stone Dust at 50% and to that proportion, percentage of fly ash (10%, 20%, 30%
and 40%) by replacing it with the ordinary Portland cement (OPC-53). And 36 cubes were cast
of M-40 Grade Concrete by fixing the percentage replacement of Sand with Quarry Stone Dust
at 25% and to that proportion, percentage of fly ash (10%, 20%, 30% and 40%) by replacing it
with the ordinary Portland cement (OPC-53). In the same way a total of 72 cylinders were cast
and tested. The specimens were cast with M-20 Grade and M-40 Grade concrete. This time 36
cylinders were cast of M-20 Grade Concrete by fixing the percentage replacement of Sand with
Quarry Stone Dust at 50% and to that proportion, percentage of fly ash (10%, 20%, 30% and
40%) by replacing it with the ordinary Portland cement (OPC-53). And 36 cylinders were cast of
M-40 Grade Concrete by fixing the percentage replacement of Sand with Quarry Stone Dust at
25% and to that proportion, percentage of fly ash (10%, 20%, 30% and 40%) by replacing it with
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the ordinary Portland cement (OPC-53). Digital compression testing machine of 3000kN
capacity was used to test all the specimens.
3.1 STUDY OF MATERIALS
The materials that are used in the study are
(1) Cement
(2) Fine Aggregate (Natural Sand)
(3) Fine Aggregate (Quarry Stone Dust)
(4) Coarse Aggregate
(5) Fly ash
(6) Water
3.1.1 Cement
In the experimental investigations ordinary Portland cement of 53 grade obtained from the Ultra
Tech Cements was used. The cement procured was tested for physical properties in accordance
with IS: 4031-1988.and is tabulated in table (3.2.1)
3.1.2 Fine Aggregate (Natural Sand)
River sand obtained from local market was used as fine aggregate in this study. The physical
properties of fine aggregate such as specific gravity, fineness modulus, porosity, void ratio etc.
were determined in accordance with IS: 2386-1963 and are shown in table (3.2.2)
3.1.3 Fine Aggregate (Quarry Stone Dust)
Quarry Stone Dust obtained from locally available quarry near Himayath sagar Dam was used
as fine aggregate in this study. The physical properties of fine aggregate such as specific gravity,
fineness modulus, porosity, void ratio etc. were determined in accordance with IS: 2386-1963
and are shown in table (3.2.3.1) and (3.2.3.2)
3.1.4 Coarse Aggregate
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20mm Coarse aggregate obtained from the local quarry has been used as coarse aggregate in the
present study. The properties of coarse aggregate like size of aggregate, shape, grading, surface
texture etc play an important role in workability and strength of concrete.
The properties of coarse aggregates are determined as follows & presented in table (3.4)
3.1.5 Fly Ash
Fly ash was obtained from NTPC Simhadri Power Plant, Vishakhapatnam, India. The Fly ash
sample is shown in plate (2).
3.1.6 Water
Potable water confirming to IS: 456-2000(7) was used for both mixing and curing. The water
was free from any objectionable materials.
3.2 Properties of materials
Table 3.1 Physical Properties of Ordinary Portland cement (OPC-53)
S.No. Property Test Method Test
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Result
1. Normal consistency Vicat apparatus (IS 4031-Part IV) 34%
2. Specific gravity Specific gravity bottle (IS 4031-Part II) 3.15
3.Initial and Final
setting timeVicat apparatus (IS 4031-Part V)
45 min
175 min
4. Fineness Sieve test on sieve no.9 (IS 4031-Part IV) 6%
Table 3.2 Properties of Fine aggregates (Natural Sand)
S.No. Property Test Result
1. Specific Gravity 2.54
2. Fineness Modulus 3.0
3. Porosity 42.8%
4. Void Ratio 0.75
5. Water Absorption 2 %
6. Moisture Content 1 %
Table 3.3 Properties of Quarry Stone Dust
S.No. Property Test Result
1. Specific Gravity 2.38
2. Porosity 0.33
3. Void Ratio 0.50
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4. Fineness Modulus 2.49
Table 3.4 Properties of Coarse aggregate.
S.No. Property Coarse aggregate
1. Specific Gravity 1.45
2. Fineness Modulus 2.85
3. Porosity 0.636
4. Void Ratio 1.75
5. Water Absorption 17.24 %
6. Moisture Content 3.45 %
7. Unit Weight 840 kg/m3
8. Oven Dry Loose Weight 780 kg/m3
9. Aggregate Crushing Value 53 %
10. Aggregate Impact Value 49 %
Table 3.5 Sieve Analysis Quarry Stone Dust
I S : Sieve Cumulative Percentage Specification as per I S : 383-1970 for fine Aggregate (% Passing) – Grading.
Retained Passing Zone-I Zone-II Zone-III Zone-IV
4.75 mm 0.2 99.8 90-100 90-100 90-100 95-100
2.36 mm 9.9 90.1 60-95 75-100 85-100 95-100
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1.18 mm 32.5 67.5 30-70 55-90 75-100 90-100
600micron 55.5 44.5 15-34 35-59 60-79 80-100
300micron 69.5 30.5 5-20 8-30 12-40 15-50
150micron 82.1 17.9 0-10 0-10 0-10 0-15
Remarks: The test sample satisfies the requirements of grading zone-II as per I S: 383-1970. According to I S:383-1970 for crushed stone sands the permissible limit on 150 micron IS Sieve is increased to 20%. This does not affect the 5% allowable permitted in CL.4.3 applying to other Sieve sizes.
3.3 MIXING OF CONCRETE
The proportioned volume of the concrete is maintained, and slump loss during transport is
minimized.
The performance of concrete is influenced by mixing and a proper and good practice of mixing
can lead to better performance and quality of the concrete. And M-20 Grade and M-40 Grade
concretes was designed using IS-456
Once the mix design is done, the mixing of the concrete can be carried out. In the present study
the mixing was carried out in an electrical drum mixer of 60 lts capacity.
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3.3.1 Procedure for mixing
The test procedure for the process of mixing is as follows
a) All the materials were weighed & prepared as per the proportion of mix design.
b) Before the mixing begins, the surface of the mixer is damped with a wet cloth.
c) The coarse aggregate is made damp by adding water as per its absorption value.
d) All the aggregates (fine & coarse) are added into the mixer till the aggregate is uniformly
distributed throughout the mixer.
e) Aggregates are mix with one-half to two-thirds of the mixing water for a short period
before adding cement, admixtures, and air-entraining admixture to minimize slump loss.
f) Cement is then added into the mixer containing the aggregates.
g) Remaining water is added into the mixer slowly while the mixing of aggregate and
cement is going on.
h) The concrete is mixed for about 5 minutes from the point of addition of water and then
the mixer is switched off.
i) The handle of the mixer is held down to allow the concrete fill into the pan.
3.3.2 Placing, Compaction and Casting of concrete specimens
Before the placing of concrete, the concrete mould must be oiled for the ease of concrete
specimen stripping. Once the workability test is done, the fresh concrete is placed into concrete
moulds to prepare specimens to test for hardened properties. Cubes of 150x150x150mm were
cast and were compacted on a table vibrator. After the filling of the mould is complete, care was
taken to level the surface.
3.4 EXPERIMENTAL PROGRAM
In this section tests on fresh and hardened concrete have been carried out. The workability tests
including slump and compaction factor are conducted on fresh concrete whereas the hardened
concrete cube specimen are tested for direct compression & split tension.
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The experimental programme of current investigation, involves the study in phases.
3.4.1 Phase – I. Determination of Compressive Strength and Split Tensile Strength of
Concrete:
In the first phase, M-20 Grade and M-40 Grade concretes have been designed using IS- .
For each of the concrete designed, four different concrete mixtures were prepared with the
percentage replacement of Natural Sand with Quarry Stone Dust (0%, 25%, 50%, 100%). For the
mixes, workability, wet and dry density, Compressive strength and Split Tensile strength at
different curing periods were determined.
3.4.2 Phase – II. Determination of Optimum Strengths with partial replacement of Cement
with fly ash:
In the second phase of test programme, fly ash concrete mixes of M-20 Grade concrete with 50%
replacement of Sand with Quarry Stone dust were designed. The fly ash concrete was varied
from 10% - 40% in steps of 10% in both strengths of concrete. Fresh concrete property of
workability was assessed for these mixes. Cube specimen of sizes 150 x 150 x 150 mm were cast
to study the strength in axial compression and split tension at 7, 14, 28 and 56 days of age. Fly
ash concrete mixes of M-40 Grade concrete with 25% replacement of Sand with Quarry Stone
dust were also designed. The fly ash concrete was varied from 10% - 40% in steps of 10% in
both strengths of concrete. Fresh concrete property of workability was assessed for these mixes.
Cube specimen of sizes 150 x 150 x 150 mm were cast to study the strength in axial compression
and split tension at 7, 14, 28 and 56 days of age. The same procedure was repeated for the
cylinders.
3.5 Tests on Fresh Concrete
The two tests, Slump and Compaction factor were employed to assess the workability of
concrete and the results are presented in tables.
3.6 Tests on Hardened Concrete specimens
In the design of concrete structures, engineers usually refer to the hardened state properties like
compressive strength, split tensile strength and flexural strength of concrete. In the present study,
experimental investigations were conducted to determine compressive strength, split tensile
23
strength of different mixes of two strength grades with different Percentage replacement of Sand
with Quarry Stone dust and fly ash percentages. For each of M-20 Grade and M-40 Grade
concretes, 4 different percentage replacements Sand with Quarry Stone Dust i.e. 0%, 25%, 50%
and 100% were employed, and 4 different percentages of fly ash i.e. 10%, 20%, 30% and 40%
were employed in Concrete to study. All the specimens are cured by Conventional wet curing.
3.6.1 Testing Procedure for Compressive Strength
The compressive strength test was performed, as per IS 516-1969, on cube specimens of size 150
x 150 x 150 mm on a digital compression testing machine of 3000 KN capacity. The specimen
after conventional water curing for 3, 7, and 28 days as of in Phase I and for 7, 14, 28 and 56
days as of in Phase II of test programme are tested under 3000 KN digital testing machine.
3.6.2 Testing Procedure for Split Tensile Strength
The split tensile strength test was performed, as per IS 5816-1970, on cube specimens of size 150
x 150 x 150 mm on a digital compression testing machine of 3000 KN capacity. The cube
specimen after conventional water curing for 7, 14, 28 and 56 days as of in Phase II of test
programme are tested under 3000 KN digital testing machine. The load at the time of failure of
specimen was recorded and split tensile strength of cube is calculated using the formula [18]:
σ sp = 0.642 P/S2
Where P is the load at failure and S is the side of the cube.
Table 3.6 Test Programme Phase I
S.NoStrength of
concreteMix
Percentage replacement of
Sand with Quarry Stone
Dust
No of cubes
1 M-20 Grade 0% 9
24
2 M-20 Grade 25% 9
3 M-20 Grade 50% 9
4 M-20 Grade 100% 9
5 M-40 Grade 0% 9
6 M-40 Grade 25% 9
7 M-40 Grade 50% 9
8 M-40 Grade 100% 9
Total 72
Table 3.7 Test Programme Phase I
S.NoStrength of
concreteMix
Percentage replacement of
Sand with Quarry Stone
Dust
No of cylinders
1 M-20 Grade 0% 9
2 M-20 Grade 25% 9
3 M-20 Grade 50% 9
4 M-20 Grade 100% 9
5 M-40 Grade 0% 9
25
6 M-40 Grade 25% 9
7 M-40 Grade 50% 9
8 M-40 Grade 100% 9
Total 72
Table 3.8 Test Programme Phase II
S.No Strength of concrete
Mix
Percentage replacement of
Sand with Quarry Stone
Dust
Percentage of Cement with Fly
Ash
No of cubes
1 M-20 Grade 50% 10 % 9
2 M-20 Grade 50% 20 % 9
3 M-20 Grade 50% 30 % 9
4 M-20 Grade 50% 40 % 9
5 M-40 Grade 25% 10 % 9
26
6 M-40 Grade 25% 20 % 9
7 M-40 Grade 25% 30 % 9
8 M-40 Grade 25% 40 % 9
Total 72
Table 3.9 Test Programme Phase II
S.No Strength of concrete
Mix
Percentage replacement of
Sand with Quarry Stone
Dust
Percentage of Cement with Fly
Ash
No of cylinders
1 M-20 Grade 50% 10 % 9
2 M-20 Grade 50% 20 % 9
3 M-20 Grade 50% 30 % 9
4 M-20 Grade 50% 40 % 9
5 M-40 Grade 25% 10 % 9
6 M-40 Grade 25% 20 % 9
27
7 M-40 Grade 25% 30 % 9
8 M-40 Grade 25% 40 % 9
Total 72
3.4 SUMMARY
In this chapter, the study of materials used, their properties, mix design, the experimental
methodology and the procedures for testing of fresh and hardened concrete are discussed. The
results of the experimental programme discussed in this chapter are tabulated and studied in the
next chapter.
28
TEST RESULTS AND DISCUSSIONS
4
CHAPTER-IV
TEST RESULTS AND DISCUSSIONS
4.0 GENERAL
29
Results obtained from experimental investigations are the compressive strengths, split tensile
strength, of various concrete mixtures of M-20 Grade and M-40 Grade strengths containing
different percentage replacement of Natural Sand with Quarry Stone Dust.
4.1 RESULTS
The test results of the experimental investigations are presented in the Tables 4.1 to 4.11. The
test results are also shown graphically in the Figures 1 to 11.
4.2 TEST RESULTS
Table 4.1 Compressive Strength of M-20 Grade Concrete
S.No
Strength of Concrete
Mix
Percentage replacement
of Sand
Compressive Strength (MPa)
7 days 14 days 28 days
1 20 MPa 0 % 24.44 32.46 36.13
2 20 MPa 25 % 20.11 33.70 37.06
3 20 MPa 50 % 26.88 34.3 37.99
30
4 20 MPa 100 % 23.16 31.12 35.28
Table 4.2 Compressive Strength of M-40 Grade Concrete
S.No
Strength of Concrete
Mix
Percentage replacement
of Sand
Compressive Strength (MPa)
7 days 14 days 28 days
1 40 MPa 0 % 42.59 54.11 61.53
2 40 MPa 25 % 45.26 50.89 64.58
3 40 MPa 50 % 41.30 52.46 59.42
4 40 MPa 100 % 35.86 43.18 45.26
Table 4.3 Split Tensile Strength of M-20 Grade Concrete
S.No
Strength of Concrete
Mix
Percentage replacement
of Sand
Split Tensile Strength (MPa)
7 days 14 days 28 days
1 20 MPa 0 % 2.21 2.95 3.28
2 20 MPa 25 % 2.25 3.07 3.30
3 20 MPa 50 % 2.44 3.09 3.53
31
4 20 MPa 100 % 1.91 2.79 3.20
Table 4.4 Split Tensile Strength of M-40 Grade Concrete
S.No
Strength of Concrete
Mix
Percentage replacement
of Sand
Split Tensile Strength (MPa)
7 days 14 days 28 days
1 40 MPa 0 % 3.41 4.32 4.95
2 40 MPa 25 % 3.95 4.63 5.12
3 40 MPa 50 % 3.15 4.21 4.32
4 40 MPa 100 % 2.83 3.40 4.13
Table 4.5 Compressive Strength of M-20 Grade Concrete with 50% replacement of Sand.
S.No
Strength of Concrete
Mix
Percentage replacement of Cement
Compressive Strength (MPa)
7 days 14 days 28 days
1 20 MPa 10 % 23.87 29.61 38.90
2 20 MPa 20 % 25.50 30.18 40.30
3 20 MPa 30 % 25.70 31.92 41.20
4 20 MPa 40 % 20.03 27.73 33.22
32
Table 4.6 Compressive Strength of M-40 Grade Concrete with 25% replacement of Sand.
S.No
Strength of Concrete
Mix
Percentage replacement of Cement
Compressive Strength (MPa)
7 days 14 days 28 days
1 40 MPa 10 % 38.18 48.82 65.33
2 40 MPa 20 % 38.24 49.11 66.28
3 40 MPa 30 % 41.28 53.73 70.58
4 40 MPa 40 % 37.03 41.41 61.90
Table 4.7 Split Tensile Strength of M-20 Grade Concrete with 50% replacement of Sand.
S.No
Strength of Concrete
Mix
Percentage replacement of Cement
Split Tensile Strength (MPa)
7 days 14 days 28 days
1 20 MPa 10 % 2.17 2.71 3.51
2 20 MPa 20 % 2.20 2.74 3.32
3 20 MPa 30 % 2.02 2.90 3.76
4 20 MPa 40 % 1.80 2.51 3.23
33
Table 4.8 Split Tensile Strength of M-40 Grade Concrete with 25% replacement of Sand.
S.No
Strength of Concrete
Mix
Percentage replacement of Cement
Split Tensile Strength (MPa)
7 days 14 days 28 days
1 40 MPa 10 % 3.01 3.91 5.18
2 40 MPa 20 % 3.15 3.98 5.34
3 40 MPa 30 % 3.28 4.13 4.72
4 40 MPa 40 % 2.92 3.70 5.03
Table 4.9 Slump Factor values of M-20 Grade and M-40 Grade Concrete with Percentage replacement of Sand.
Strength of
Concrete
Mix
Slump value in mm with percentage replacement of Sand
0 % 25 % 50 % 100 %
20 MPa 95 94 97 98
40 MPa 76 79 74 81
Table 4.10 Slump Factor values of M-20 Grade and M-40 Grade Concrete with Fixed percentage replacement of Sand and replacement of Cement.
34
Strength of
Concrete
Mix
Slump value in mm with percentage replacement of Sand
0 % 25 % 50 % 100 %
20 MPa 95 94 97 98
40 MPa 76 79 74 81
Table 4.11Compaction Factor values of M-20 Grade and M-40 Grade Concrete with Percentage replacement of Sand.
Strength of
Concrete
Mix
Compaction value with percentage replacement of Sand
0 % 25 % 50 % 100 %
20 MPa 0.8 0.8 0.8 0.8
40 MPa 0.9 0.9 0.9 0.9
35
Fig. 1 Variation of Compressive Strength with Percentage replacement of Sand with QD
for M-20 Grade Concrete.
36
Fig. 2 Variation of Compressive Strength with Percentage replacement of Sand with QD
for M-40 Grade Concrete.
Fig. 3 Variation of Split Tensile Strength with Percentage replacement of Sand with QD
for M-20 Grade Concrete.
37
Fig. 4 Variation of Split Tensile Strength with Percentage replacement of Sand with QD
for M-40 Grade Concrete.
Fig. 5 Variation of Compressive Strength for 50% replacement of Sand with Percentage
replacement of Cement for M-20 Grade Concrete.
38
Fig. 6 Variation of Compressive Strength for 25% replacement of Sand with Percentage
replacement of Cement for M-40 Grade Concrete.
Fig. 7 Variation of Split Tensile Strength for 50% replacement of Sand with Percentage
replacement of Cement for M-20 Grade Concrete.
39
Fig. 8 Variation of Split Tensile Strength for 25% replacement of Sand with Percentage
replacement of Cement for M-40 Grade Concrete.
Fig. 9 Variation of Slump Factor Values for M-20 Grade and M-40 Grade Concrete with
percentage replacement of Sand.
40
Fig. 10 Variation of Slump Factor Values for M-20 Grade Concrete with 50% replacement
of Sand and M-40 Grade Concrete with 25% replacement of Sand and Variation
percentage replacement of Cement.
Fig. 11 Variation of Compaction Factor Values for M-20 Grade and M-40 Grade Concrete
with percentage replacement of Sand.
41
4.3 Discussion:
4.3.1 Effect of Quarry Stone Dust Percentage on Compressive strength of Conventional
Concrete (20 Mpa ):
Fig (1) depicts the variation of compressive strength for M-20 Grade concrete prepared with
different percentages of Quarry Stone Dust and cured by conventional wet curing. The
compressive strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone
Dust meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The
compressive strength of 0%, 25% and 50% Quarry Stone Dust mix concrete were found to
increase from 36.13Mpa, 37.06Mpa and 37.99Mpa respectively. The compressive strength of
50% to 100% Quarry Stone Dust mix concrete were found to decrease from 37.99Mpa to
35.28Mpa respectively. It could be observed that optimum strength is obtained for M-20 Grade
concrete at 50% Quarry Stone Dust and the strength gets depletes with the use of higher
percentages of Quarry Stone Dust in concrete.
4.3.2 Effect of Quarry Stone Dust Percentage on Split Tensile strength of Conventional
Concrete ( 20 Mpa ):
42
Fig (3) depicts the variation of Split Tensile strength for M-20 Grade concrete prepared with
different percentages of Quarry Stone Dust and cured by conventional wet curing. The Split
Tensile strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone Dust
meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The Split Tensile
strength of 0%, 25% and 50% Quarry Stone Dust mix concrete were found to increase from
3.28Mpa, 3.30Mpa and 3.53Mpa respectively. The Split Tensile strength of 50% to 100% Quarry
Stone Dust mix concrete were found to decrease from 3.53Mpa to 3.M-20 Grade respectively.
It could be observed that optimum strength is obtained for M-20 Grade concrete at 50% Quarry
Stone Dust and the strength gets depletes with the use of higher percentages of Quarry Stone
Dust in concrete.
4.3.3 Effect of Quarry Stone Dust Percentage on Compressive strength of High Strength
Concrete ( 40 Mpa ):
Fig (2) depicts the variation of compressive strength for M-40 Grade concrete prepared with
different percentages of Quarry Stone Dust and cured by conventional wet curing. The
compressive strengths obtained for concrete mix with 0% and 25%, 50% and 100% Quarry
Stone Dust meets the desired characteristic strength of 20 N/mm2 beyond 28 days of age. The
compressive strength of 0% and 25% Quarry Stone Dust mix concrete were found to increase
from 61.53Mpa to 64.58Mpa respectively. The compressive strength of 25%, 50% and 100%
Quarry Stone Dust mix concrete were found to decrease from 64.58Mpa, 59.42Mpa and
45.26Mpa respectively. It could be observed that optimum strength is obtained for M-40 Grade
concrete at 25% Quarry Stone Dust and the strength gets depletes with the use of higher
percentages of Quarry Stone Dust in concrete.
4.3.4 Effect of Quarry Stone Dust Percentage on Split Tensile strength of High Strength
Concrete ( 40 Mpa ):
43
Fig (4) depicts the variation of Split Tensile strength for M-40 Grade concrete prepared with
different percentages of Quarry Stone Dust and cured by conventional wet curing. The Split
Tensile strengths obtained for concrete mix with 0%, 25%, 50% and 100% Quarry Stone Dust
meets the desired characteristic strength of 40 N/mm2 beyond 28 days of age. The Split Tensile
strength of 0%, and 25% Quarry Stone Dust mix concrete were found to increase from 4.95Mpa
to 5.12Mpa respectively. The Split Tensile strength of 25%, 50% and 100% Quarry Stone Dust
mix concrete were found to decrease from 5.12Mpa, 4.32Mpa, and 4.13Mpa respectively. It
could be observed that optimum strength is obtained for M-40 Grade concrete 25% Quarry Stone
Dust and the strength gets depletes with the use of higher percentages of Quarry Stone Dust in
concrete.
4.3.5 Effect of Fly Ash Percentage on Compressive strength of Conventional Concrete
( M-20 Grade ):
Fig (5) depicts the variation of compressive strength for M-20 Grade concrete with 50%
replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by
conventional wet curing. The compressive strengths obtained for concrete mix with 10%, 20%,
30% and 40% fly ash meets the desired characteristic strength of 20 N/mm2 beyond 28 days of
age. The compressive strength of 10%, 20% and 30% fly ash mix concrete were found to be
increase from 38.90Mpa, 40.30Mpa and 41.M-20 Grade respectively. The compressive strength
of 30% and 40% fly ash mix is found to decrease from 41.M-20 Grade to 33.22Mpa
respectively. It could be observed that optimum strength is obtained for concrete with 30% fly
ash and the strength gets depletes with the use of higher percentages of fly ash in concrete.
4.3.6 Effect of Fly Ash Percentage on Split Tensile strength of Conventional Concrete
(M-20 Grade):
Fig (7) depicts the variation of Split Tensile strength for M-20 Grade concrete with 50%
replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by 44
conventional wet curing. The Split Tensile strengths obtained for concrete mix with 10%, 20%,
30% and 40% fly ash meets the desired characteristic strength of 20 N/mm2 beyond 28 days of
age. The Split Tensile strength of 10%, 20% and 30% fly ash mix concrete were found to be
increase from 3.51Mpa, 3.32Mpa and 3.76Mpa respectively. The Split Tensile strength of 30%
and 40% fly ash mix is found to decrease from 3.76Mpa to 3.23Mpa respectively. It could be
observed that optimum strength is obtained for concrete with 30% fly ash and the strength gets
depletes with the use of higher percentages of fly ash in concrete.
4.3.7 Effect of Fly Ash Percentage on Compressive strength of High Strength Concrete
(M-40 Grade):
Fig (6) depicts the variation of compressive strength for M-40 Grade concrete with 25%
replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by
conventional wet curing. The compressive strengths obtained for concrete mix with 10%, 20%,
30% and 40% fly ash meets the desired characteristic strength of 40 N/mm2 beyond 28 days of
age. The compressive strength of 10%, 20% and 30% fly ash mix concrete were found to be
increase from 65.33Mpa, 66.28Mpa and 70.58Mpa respectively. The compressive strength of
30% and 40% fly ash mix is found to decrease from 70.58Mpa to 61.90Mpa respectively. It
could be observed that optimum strength is obtained for concrete with 30% fly ash and the
strength gets depletes with the use of higher percentages of fly ash in concrete.
4.3.8 Effect of Fly Ash Percentage on Split Tensile strength of High Strength Concrete
(M-40 Grade):
Fig (8) depicts the variation of Split Tensile strength for M-40 Grade concrete with 25%
replacement with Quarry Stone Dust prepared with different percentages of fly ash and cured by
conventional wet curing. The Split Tensile strengths obtained for concrete mix with 10%, 20%,
30% and 40% fly ash meets the desired characteristic strength of 40 N/mm2 beyond 28 days of
age. The Split Tensile strength of 10%, 20% and 30% fly ash mix concrete were found to be 45
increase respectively. The Split Tensile strength of 30% and 40% fly ash mix is found to
decrease from respectively. It could be observed that optimum strength is obtained for concrete
with 30% fly ash and the strength gets depletes with the use of higher percentages of fly ash in
concrete.
4.3 SUMMARY
In this chapter, the results obtained from the experimental programme are tabulated and
are represented in the form of graphs. The results were studied and based on the study, the
conclusions were drawn. The conclusions of the present work are given in the next chapter.
Plate 1. Sample of Quarry Stone Dust Aggregate
46
Plate 2. Sample of Fly Ash
Plate 3. Electrical Drum Mixer of 60 lts capacity
47
Plate 4. Moulds kept on Vibrator
Plate 5. Curing Tank
48
Plate 6. Compression Testing Machine
49
CONCLUSIONS
50
CHAPTER-V
CONCLUSIONS
5.1 GENERAL
Studies have been carried out on natural aggregate, percentage replacement of Natural
sand by Quarry stone dust. Fly Ash as partial replacement of cement with various percentages of
Quarry stone dust. The parameters studied include Quarry Stone dust, Fly ash content. Based on
the study conducted, the conclusions are drawn.
5.2 CONCLUSIONS
Based on the study conducted on M-20 Grade and M-40 Grade concretes with Quarry Stone
Dust aggregate of different percentage replacements, the following conclusions are drawn:
• Compressive Strength values increase with the percentage replacement of Natural Sand
with Quarry Stone Dust upto 50% and decrease upon further replacement for Conventional
Concrete M-20 Grade.And the values increase with the percentage replacement of Natural
Sand with Quarry Stone Dust upto 25% and decrease upon further replacement for High
Strength Concrete M-40 Grade.
• Split Tensile Strength values increase with the percentage replacement of Natural Sand
with Quarry Stone Dust upto 50% and decrease upon further replacement for Conventional
Concrete M-20 Grade.And the values increase with the percentage replacement of Natural
Sand with Quarry Stone Dust upto 25% and decrease upon further replacement for High
Strength Concrete M-40 Grade.
51
• M-20 Grade concrete with fly ash replacement, attained the optimum compressive and split
tensile strengths at 28 days of age with 30% replacement of cement with fly ash.
• M-40 Grade concrete with fly ash replacement, attained the optimum compressive and split
tensile strengths at 28 days of age with 30% replacement of cement with fly ash.
• For M-20 Grade concretes, compressive and split tensile strengths decreased with increase
in percentage replacement of cement by fly ash after 30% replacement.
• For M-40 Grade concretes, compressive and split tensile strengths decreased with increase
in percentage replacement of cement by fly ash after 30% replacement.
5.3 SCOPE FOR FUTHER INVESTIGATION
• It is advisable to continue the procedure by replacing the percentages of Fly ash in the
percentages (10%, 20%, 30%, 40%) for all the percentages of replacement of Natural Sand
with Quarry Stone dust of (0%, 25%, 50%, 100%) for Conventional Concrete M-20 Grade.
• It is advisable to continue the procedure by replacing the percentages of Fly ash in the
percentages (10%, 20%, 30%, 40%) for all the percentages of replacement of Natural Sand
with Quarry Stone dust of (0%, 25%, 50%, 100%) for High Strength Concrete M-40 Grade.
Studies have been carried out on conventional concrete and high strength concrete with
Natural Fine aggregate, percentage replacement of Natural fine aggregate by Quarry stone dust
aggregate and Fly Ash with cement. The parameters studied include Fly ash and quantity of
Quarry stone dust aggregate. The results show the variation of the strengths in concrete.
52
BIBLIOGRAPHY
53
BIBLIOGRAPHY
1. M Shahul Hameed, A.S.S.Sekar, (2009) “Properties of Green Concrete Containing
Quarry Rock Dust and Marble Sludge Powder as Fine Aggregates”, ARPN Journal of
Engineering and Applied Sciences, Vol. 4, No 4.
2. R.Ilangovana, N. Mahendrana and K Nagamanib, “Strength and Durability
Properties of Concrete containing Quarry Rock Dust as Fine Aggregate”, ARPN
Journal of Engineering and Applied Sciences, Vol. 3, No 5, 2008.
3. Norazila Binti Kamarulzaman, “An Investigation on Effect of Quarry Dust as Sand
replacement on Compressive and Flexural Strength of Foam Concrete”, Universiti
Malaysia Pahang, 2010.
4. Radhikesh P. Nanda, Amiya K. Das, Moharana.N.C, “Stone Crusher Dust as a
Fine Aggregate in Concrete for Paving Blocks”, International Journal of Civil and
Structural Engineering, Vol 1, No 3,2010.
5. Manasseh JOEL, “Use of Crushed Granite fine as replacement to River Sand in
Concrete Production”, Leonardo Electronic Journal of Practices and Technologies,
2010.
6. Raman S.N, Safiuddin M, Zain M.F.M, “Non-Destructive evaluation of Flowing
concretes incorporating quarry waste”, Asian Journal of Civil Engineering (Building
and Housing), 2007,8(6), p.597-614.
7. Uchikawa H.S, Hanehara Hirao H, “Influence of microstructure on the physical
properties of concrete prepared by substituting material powder for part of fine
aggregate, Cement and Concrete Research, 1996,26(1), p.101-111.
8. Siddique R, “Effect of Fine Aggregate replacement with Class F fly ash on the
Mechanical properties of Concrete”. Cement and Concrete Research, 2003, 33(4).
9. Nagaraj T.S, Banu Z, “Effective Utilization of rock dust and Pebbles as Aggregate
in Portland Cement Concrete”. The Indian Concrete Journal, 1996, 70(1).
10. Safiuddin M.D, Raman S.N, Zain M.F.M, “Utilization of Quarry Waste Fine
Aggregate in Concrete Mixtures”, Journal of Applied Sciences Research, Instinet
Publications, 2007, vol 5(13), pp no.1952-1963.
54
11. Murdock L.J, Brook K.M, Dewar J.D, Concrete Material and Practice. Edward
Arnold London, 1991.
12. Neville. A.M., “Properties of Concrete”, 4th Edition, Pitman Publishing Limited,
London 1997.
13. Gambhir M.L. “Concrete Technology”, 3rd Edition, The McGraw Hill Companies,
New Delhi, 2004.
14. Mindess S, Young JF, Concrete. Englewood Cliffs, NJ: Prentice Hall; 1981.
55
APPENDIX
56
APPENDIX
Mix design for Structural Concrete: (As per I S Code : SP 23-1982)
Before having any concrete mixing, the selection of mix materials and their required materials
proportion must be done through a process called mix design. In the present study I S Code
method for Concrete has been adopted and altogether sixteen batches of mixtures were
determined. The grade of concrete is of M-20 Grade and M-40 Grade Strengths.
In the first phase, concrete mix design using eight different concrete mix (M-1) of M-20 Grade
and M-40 Grade strengths with the exclusive use of 20mm down aggregates. And in the second
phase, fly ash concrete mixes of M-20 Grade and M-40 Grade concrete with aggregate of size
resulting in optimum strength were designed.
Mix Design for M-20 Grade Strength:
Mix M-1:
a) Design Stipulations:
I. Characteristic Strength required at 28 days = M-20 Grade.
II. Maximum size of Aggregates = 20 mm (Angular).
III. Degree of Quality control = Good.
IV. Type of Exposure = Mild.
b) Test data for Materials:
I. Specific Gravity of Cement = 3.15.
II. Specific Gravity of Coarse Aggregates = 2.55.
III. Specific Gravity of Fine Aggregates = 2.65.
IV. Water Absorbtion.
57
1) Coarse Aggregates = 0.5 %
2) Fine Aggregates = 1.0 %
V. Free Surface Moisture.
1) Coarse Aggregates = Nil.
2) Fine Aggregates = 2.0 %
VI. Sieve Analysis of a Sand Confirming to Zone-III.
VII. Target mean strength of Concrete.
20+ (1.65x4) = 26.6 Mpa.
VIII. Selection of water cement ratio
W/C = 0.50.
IX. Selection of water and sand content
Standard for zone II
Water Content per cubic meter = 186 Lts.
Sand content as percentage of total Aggregates = 35 %.
For Change in Values of w/c ratio, Compacting factor for Zone-III
58
Change Conditions Adjustments
Water Content Percentage Sand in Total
Aggregates.
For Sand Confirming to
Zone III
0 -2
For Increase in
Compacting factor
+3 0
For Decrease in Water –
Cement ratio by (0.6-0.5)
that is 0.1
0 -1.5
Total +3 -3.5
Therefore required sand content as percentage of total aggregate by absolute volume : 35-3.5 =
31.5%.
Required Water content : 186 + 5.58 = 191.6 L/m3.
X. Determination of Cement content
W/C = 0.5
Water = 191.6 Lts
Therefore Cement = 191.6/0.5 = 383 kg/m3
This Cement content is adequate for mild exposure.
XI. Determination of Fine Aggregates.
0.98 = (191.6 + (383/3.15) + ((1/0.315)x(fa/2.6)) x (1/1000)
59
Fa = 546 kg/m3
XII. Determination of Coarse Aggregates.
0.98 = (191.6 + (383/3.15) + ((1/0.685)x(Ca/2.6)) x (1/1000)
Ca = 1188 kg/m3
The Mix proportion than becomes
Water : 191.6 : 0.50
Cement : 383 kg : 1
Fine Aggregates 546 kg : 1.425
Coarse Aggregates 1188 kg : 3.10
Mix Design for M-40 Grade Strength:
Mix M-2:
c) Design Stipulations:
I. Characteristic Strength required at 28 days = M-40 Grade.
60
II. Maximum size of Aggregates = 20 mm (Angular).
III. Degree of Quality control = Good.
IV. Type of Exposure = Mild.
d) Test data for Materials:
V. Specific Gravity of Cement = 3.15.
VI. Specific Gravity of Coarse Aggregates = 2.55.
VII. Specific Gravity of Fine Aggregates = 2.65.
VIII. Water Absorption.
3) Coarse Aggregates = 0.5 %
4) Fine Aggregates = 1.0 %
IX. Free Surface Moisture.
3) Coarse Aggregates = Nil.
4) Fine Aggregates = 2.0 %
X. Sieve Analysis of a Sand Confirming to Zone-III.
XI. Target mean strength of Concrete.
40+ (1.65x5) = 48.25 Mpa.
XII. Selection of water cement ratio
W/C = 0.31.
XIII. Selection of water and sand content
Standard for zone II
61
Water Content per cubic meter = 186 Lts.
Sand content as percentage of total Aggregates = 35 %.
For Change in Values of w/c ratio, Compacting factor for Zone-III
Change Conditions Adjustments
Water Content Percentage Sand in Total
Aggregates.
For Sand Confirming to
Zone III
0 -1.5
For Increase in
Compacting factor
+3 0
For Decrease in Water –
Cement ratio by (0.6-0.5)
that is 0.1
0 -5.8
Total +3 -7.3
Therefore required sand content as percentage of total aggregate by absolute volume : 35-7.3 =
27.7%.
Required Water content : 186 + 5.58 = 191.6 L/m3.
XIV. Determination of Cement content
W/C = 0.31
Water = 191.6 Lts
Therefore Cement = 191.6/0.31 = 618.064 kg/m3
Cement as per IS Code content should not exceed 450 kg/m3.
Therefore Correcting Cement
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Cement = 450 kg/m3
W/C = 0.31
Water = 0.31 x 450
= 139.5 L/m3
XV. Determination of Fine Aggregates.
0.98 = (139.5 + (450/3.15) + ((1/0.277)x(fa/2.65)) x (1/1000)
Fa = 512.42 kg/m3
XVI. Determination of Coarse Aggregates.
0.98 = (139.5 + (450/3.15) + ((1/0.723)x(Ca/2.55)) x (1/1000)
Ca = 1286.22 kg/m3
The Mix proportion than becomes
Water: 139.5 : 0.31
Cement: 450 kg : 1
Fine Aggregates 512.42 kg : 1.138
Coarse Aggregates 1286.22 kg : 2.858.
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